Battery Cell Terminal Sealing via Compressive Force

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Solution Overview

Problem

Existing battery systems for electric vehicles face challenges in increasing travel distance, improving performance, and reducing costs while maintaining reliability across various environmental conditions, particularly in sealing battery terminals to prevent moisture ingress and electrolyte leakage.

Innovation Solution

The use of a battery cell design featuring a packaging with a terminal port sealed using a compressive force, such as a press-fit ring, which allows for efficient manufacturing and reduces the need for welding, thereby enhancing the battery cell's hermetic sealing and energy density.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If welding is used to seal battery terminals, then hermetic sealing is achieved, but manufacturing time and costs increase

Engineering Contradiction:

Improvehermetic sealingVSAvoidmanufacturing time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The patent replaces the welding process (thermal/chemical system) with a mechanical compression system using a compressive force applied through a sealing structure. This mechanical substitution eliminates the need for welding operations while achieving hermetic sealing through direct compression of the terminal against the packaging material, thereby reducing manufacturing time and complexity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces a sealing structure as an intermediary element between the battery terminal and the packaging. This intermediary component facilitates hermetic sealing by distributing the compressive force evenly across the terminal-packaging interface, enabling effective sealing without requiring welding operations.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If welding is used to seal battery terminals, then hermetic sealing is achieved, but manufacturing costs increase

Engineering Contradiction:

Improvehermetic sealingVSAvoidmanufacturing costs

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent employs a sealing structure that can be manufactured at low cost using simple compression molding techniques. This sealing component serves as a cost-effective alternative to welding, providing hermetic sealing functionality without the high equipment and operational costs associated with welding processes.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Productivity

If compressive force is used for hermetic sealing, then manufacturing efficiency is improved, but sealing reliability may be compromised

Engineering Contradiction:

Improvemanufacturing efficiencyVSAvoidsealing reliability

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent applies compressive force locally at the terminal-packaging interface through a sealing structure rather than requiring uniform compression across the entire battery cell. This localized application of force ensures hermetic sealing at the critical terminal penetration point while maintaining manufacturing efficiency. The sealing structure concentrates the compressive force where it is most needed to prevent moisture ingress and electrolyte leakage.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The sealing structure incorporates curved or rounded surfaces that distribute the compressive force evenly across the terminal interface. This geometric design prevents stress concentration and ensures uniform sealing contact, thereby maintaining sealing reliability while using a simple compression process.

Inventive Principle:

Principle #14Spheroidality (Curvature)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This solution enables reliable hermetic sealing of battery terminals, reduces manufacturing time and costs, and improves energy density, allowing for better performance and durability across diverse environmental conditions.

Implementation Method 1

sealed using a compressive force

Methodology Applied

Scientific EffectCompressive force: Compression

Data Source

PatentEP2810319B1Battery cells and method for manufacturing battery cells

Publication Date: 2022.06.15 CPS TECHNOLOGY HOLDINGS LLC

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AI summary

A system includes a battery cell having a packaging and a coil disposed within the packaging. The battery cell further includes a first terminal electrically coupled to a portion the coil and protruding through an opening in the packaging, wherein the first terminal is hermetically sealed at the opening in the packaging using a compressive force.